Hinging drywall apparatus and method

Abstract

A drywall system is provided including a first drywall panel and a second drywall panel connected to the first drywall panel via a main hinge. A first drywall flap connected to the first drywall panel via a first hinge, and a second drywall flap connected to the second drywall panel via a second hinge. The first drywall panel, the second drywall panel, the first drywall flap and the second drywall flap can hinge to assume at least one corner configuration in which the first and second flaps lie on a first plane, the first drywall panel lies on a second plane and the second drywall panel lies on a third plane, such that the first plane, the second plane and the third plane are mutually orthogonal. A coating can be provided on an external surface of the framing drywall liner for strengthening the groove which, in embodiments can be polyester strip that extends over portions of the first and second gypsum-containing segments on either side of the of the groove.

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         18 . A method of constructing a hingeable drywall apparatus comprising: providing a finishing drywall liner having an internal side and an external side; pouring gypsum slurry onto the internal side of the finishing drywall liner; forming a first groove on a framing drywall liner, the first groove having a shape; placing the framing drywall liner on the gypsum slurry so that the gypsum slurry is sandwiched between the finishing drywall liner and the framing drywall liner; and allowing the gypsum slurry to set to a hardened gypsum material, wherein, during the step of allowing, the shape of the first groove is impressed upon the slurry resulting in a second groove in the hardened gypsum material that mates with the first groove to thereby form a hinge at the first and second grooves, wherein said first and second grooves give rise to two segments of the apparatus that can rotate about the hinge. 
     
     
         19 . The method of  claim 18 , wherein the step of placing is executed before the step of forming. 
     
     
         20 . The method of  claim 18 , further comprising, after the step of placing, dividing the framing drywall liner in the groove. 
     
     
         21 . The method of  claim 20 , wherein the step of dividing is performed with at least one of a saw and a router. 
     
     
         22 . The method of claim  15 , further comprising: from one of the two segments, forming a first drywall flap that is hingeable via a first hinge; from the other of the two segments, forming a second drywall flap that is hingeable via a second hinge; and affixing the drywall apparatus to framing members to form a corner, such that the hinge, the first hinge and that second hinge are mutually perpendicular. 
     
     
         23 . The method of  claim 22 , further comprising: during the step of forming a first drywall flap, shaping the first drywall flap into a right-angled isosceles triangle; and during the step of forming a second drywall flap, shaping the second drywall flap into a right-angled isosceles triangle. 
     
     
         24 . The method of  claim 22 , further comprising affixing the drywall apparatus to framing members to form a corner, such that the first flap and the second flap lie on one plane, one of the two segments lies on a second plane and the other one of the two segments lies on a third plane such that the first plane, the second plane and the third plane are mutually orthogonal. 
     
     
         25 . The method of  claim 18 , further comprising: from one of the two segments, forming a drywall flap that is hingeable via a flap hinge; from the other of the two segments, forming a trapezoid with four sides, only two of the four sides being parallel; and affixing the drywall apparatus to framing members to form a frame for a window. 
     
     
         26 . The method of  claim 18 , further comprising strengthening the hinge by applying a coating on an external surface of the framing drywall liner at the groove. 
     
     
         27 . The method of  claim 26 , wherein the coating comprises a polyester strip that extends over portions of the first and second gypsum-containing segments on either side of the of the groove. 
     
     
         28 . The method of  claim 27 , wherein the polyester strip comprises BoPET (Biaxially-oriented polyethylene terephthalate). 
     
     
         29 . The method of  claim 27 , further comprising perforating the framing drywall liner on both sides of the first groove intermediate edges of the polyester strip and a largest width of the first groove. 
     
     
         30 . The method of  claim 29 , further comprising removing a strip between two lines created by perforating the framing drywall liner to reveal the polyester strip. 
     
     
         31 . The method of  claim 27 , wherein the polyester strip is heat resistant. 
     
     
         32 . The method of  claim 27 , wherein the polyester strip is coated with a resin having a high heat deflection temperature. 
     
     
         33 . The method of  claim 27 , further including a coating of adhesive applied to the first and second gypsum-containing segments for bonding the polyester to the first and second gypsum-containing segments. 
     
     
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